ls10 premelter for muller martini -...

LS10E PreMelterfor Muller Martini

Customer Product ManualPart 1038988C

Issued 9/05

NORDSON CORPORATION • DULUTH, GEORGIA • USAwww.nordson.com

Part 1038988C � 2005 Nordson Corporation

Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General informationabout Nordson can be found on the Internet using the following address: http://www.nordson.com.

Address all correspondence to:

Nordson CorporationAttn: Customer Service11475 Lakefield Drive

Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2003.No part of this document may be photocopied, reproduced, or translated to another language without the prior written

consent of Nordson Corporation. The information contained in this publication is subject to change without notice.

© 2003 All rights reserved.

Trademarks

AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve, CleanSpray,ColorMax, Control Coat, Coolwave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura-Screen, Durasystem, Easy Coat,Easymove Plus, Ecodry, Econo-Coat, e.dot, EFD, ETI, e.Stylized, Excel 2000, Fillmaster, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry, Fluidmove,

FoamMelt, FoamMix, Heli-flow, Helix, Horizon, Hot Shot, iControl, iFlow, Isocoil, Isocore, Iso-Flo, iTRAX, Kinetix, Little Squirt, Magnastatic, March, MEG,Meltex, Microcoat, Micromark, MicroSet, Millennium, Mini Squirt, Mountaingate, MultiScan, Nordson, OptiMix, Package of Values, Pattern View, PermaFlo,Plasmod, Porous Coat, PowderGrid, Powderware, Printplus, Prism, ProBlue, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Scoreguard,Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, SureBead, Sure Clean, Sure Coat,Sure-Max, Tracking Plus, Trends, Tribomatic, Ultrasaver, UpTime, Veritec, VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, and

When you expect more. are registered trademarks of Nordson Corporation.

Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AquaCure, ATS, Auto-Flo, AutoScan, Blue Series, Check Mate, Classicblue,Controlled Fiberization, Control Weave, CPX, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraDrum, DuraPail, Easy Clean, EasyOn, Eclipse, E-Nordson,

Equi=Bead, ESP, Fill Sentry, G−Net, G−Site, HDLV, iON, Iso-Flex, iTrend, Lacquer Cure, Lean Cell, Logicomm, Maverick, Maxima, MicroFin, MicroMax,MiniBlue, Minimeter, Multifil, Myritex, OptiStroke, PatternPro, PCI, Powder Pilot, Powercure, Primarc, Process Sentry, Prodigy, Pulse Spray, Quad Cure,Ready Coat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit,

Sure Brand, SureSeal, Sure Wrap, Swirl Coat, Tempus, ThruWave, Trade Plus, Trak, TrueBlue, Ultra, Ultrasmart, Universal, Vantage, Vista, Web Cure, and2 Rings (Design) are trademarks of Nordson Corporation.

Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners’ rights.

Table of Contents i

Part 1038988B� 2005 Nordson Corporation

Table of Contents

Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Alert Symbols 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Responsibilities of the Equipment Owner 2. . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instructions, Requirements, and Standards 2. . . . . . . . . . . . . . . . . . . . . . User Qualifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicable Industry Safety Practices 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intended Use of the Equipment 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instructions and Safety Messages 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Practices 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Practices 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Repair Practices 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Safety Information 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Shutdown 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Safety Warnings and Cautions 6. . . . . . . . . . . . . . . . . . . . . . . . . Other Safety Precautions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Aid 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Features 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Block Diagram 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Physical 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performance 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Installation 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic System - Hoses 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Circuits and Wiring 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Requirements 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Schematic and Motor Wiring Diagram 17. . . . . . . . . . . . . . . . . . Electrical Connections 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Control of Pump Motor for Automatic Systems 19. . . . . . . . . . .

Table of Contentsii

Part 1038988B � 2005 Nordson Corporation

Operation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls and Indicators 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Power Switch/Circuit Breaker/Power ON Indicator 20. . . . . . . . . Tank Over-temperature Indicator 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Temperature Gauge 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Temperature Controller (not shown) 20. . . . . . . . . . . . . . . . . . . . . . . . Hose Temperature Controller (not shown) 21. . . . . . . . . . . . . . . . . . . . . . . Tank Heating Indicator 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Motor Switch/Circuit Breaker 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Adjustments 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Temperature Controller 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose Temperature Controller 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive Maintenance 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat Hose – Male Connector Pin Location and Function 29. . . . .

Repair and Replacement 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose Replacement 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Hose 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Hose 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hose Temperature Controller Replacement 34. . . . . . . . . . . . . . . . . . . . . . . . Tank Temperature Controller Replacement 35. . . . . . . . . . . . . . . . . . . . . . . . . Tank Heater Replacement 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Over-temperature Thermostat Replacement 37. . . . . . . . . . . . . . . . . . . Pump warm-up Thermostat Replacement 38. . . . . . . . . . . . . . . . . . . . . . . . . . V4 Pump Replacement 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Motor and Pump Shaft Assembly Replacement 40. . . . . . . . . . . . . . . Fuse Replacement 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts List 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Systems Components 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Spares 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose and Tank Temperature Controllers and Tank Heaters 46. . . . . . . . . . . Tank Over-temperature and Pump Warm-up Thermostat 47. . . . . . . . . . . . . Motor Assembly 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V4 Pump 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Shaft Assembly 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LS10E Pre-Melter (Muller Martini) 1

Part 1038988C� 2005 Nordson Corporation

LS10E Pre-Melter (Muller Martini)

Safety Read this section before using the equipment. This section containsrecommendations and practices applicable to the safe installation,operation, and maintenance (hereafter referred to as “use”) of the productdescribed in this document (hereafter referred to as “equipment”).Additional safety information, in the form of task-specific safety alertmessages, appears as appropriate throughout this document.

WARNING: Failure to follow the safety messages, recommendations, andhazard avoidance procedures provided in this document can result inpersonal injury, including death, or damage to equipment or property.

Safety Alert Symbols The following safety alert symbol and signal words are used throughout thisdocument to alert the reader to personal safety hazards or to identifyconditions that may result in damage to equipment or property. Comply withall safety information that follows the signal word.

WARNING: Indicates a potentially hazardous situation that, if not avoided,can result in serious personal injury, including death.

CAUTION: Indicates a potentially hazardous situation that, if not avoided,can result in minor or moderate personal injury.

CAUTION: (Used without the safety alert symbol) Indicates a potentiallyhazardous situation that, if not avoided, can result in damage to equipmentor property.

LS10E Pre-Melter (Muller Martini)2


Responsibilities of the Equipment Owner Equipment owners are responsible for managing safety information,ensuring that all instructions and regulatory requirements for use of theequipment are met, and for qualifying all potential users.

Safety Information � Research and evaluate safety information from all applicable sources,

including the owner-specific safety policy, best industry practices,governing regulations, material manufacturer’s product information, andthis document.

� Make safety information available to equipment users in accordancewith governing regulations. Contact the authority having jurisdiction forinformation.

� Maintain safety information, including the safety labels affixed to theequipment, in readable condition.

Instructions, Requirements, and Standards � Ensure that the equipment is used in accordance with the information

provided in this document, governing codes and regulations, and bestindustry practices.

� If applicable, receive approval from your facility’s engineering or safetydepartment, or other similar function within your organization, beforeinstalling or operating the equipment for the first time.

� Provide appropriate emergency and first aid equipment.

� Conduct safety inspections to ensure required practices are beingfollowed.

� Re-evaluate safety practices and procedures whenever changes aremade to the process or equipment.



User Qualifications Equipment owners are responsible for ensuring that users:

� receive safety training appropriate to their job function as directed bygoverning regulations and best industry practices

� are familiar with the equipment owner’s safety and accidentprevention policies and procedures

� receive, equipment- and task-specific training from another qualifiedindividual

NOTE: Nordson can provide equipment-specific installation,operation, and maintenance training. Contact your Nordsonrepresentative for information

� possess industry- and trade-specific skills and a level of experienceappropriate to their job function

� are physically capable of performing their job function and are notunder the influence of any substance that degrades their mentalcapacity or physical capabilities

Applicable Industry Safety Practices The following safety practices apply to the use of the equipment in themanner described in this document. The information provided here is notmeant to include all possible safety practices, but represents the best safetypractices for equipment of similar hazard potential used in similar industries.

Intended Use of the Equipment � Use the equipment only for the purposes described and within the limits

specified in this document.

� Do not modify the equipment.

� Do not use incompatible materials or unapproved auxiliary devices.Contact your Nordson representative if you have any questions onmaterial compatibility or the use of non-standard auxiliary devices.

Instructions and Safety Messages � Read and follow the instructions provided in this document and other

referenced documents.

� Familiarize yourself with the location and meaning of the safety warninglabels and tags affixed to the equipment. Refer to Safety Labels andTags at the end of this section.

� If you are unsure of how to use the equipment, contact your Nordsonrepresentative for assistance.



Installation Practices � Install the equipment in accordance with the instructions provided in this

document and in the documentation provided with auxiliary devices.

� Ensure that the equipment is rated for the environment in which it will beused and that the processing characteristics of the material will notcreate a hazardous environment. Refer to the Material Safety DataSheet (MSDS) for the material.

� If the required installation configuration does not match the installationinstructions, contact your Nordson representative for assistance.

� Position the equipment for safe operation. Observe the requirements forclearance between the equipment and other objects.

� Install lockable power disconnects to isolate the equipment and allindependently powered auxiliary devices from their power sources.

� Properly ground all equipment. Contact your local building codeenforcement agency for specific requirements.

� Ensure that fuses of the correct type and rating are installed in fusedequipment.

� Contact the authority having jurisdiction to determine the requirement forinstallation permits or inspections.

Operating Practices � Familiarize yourself with the location and operation of all safety devices

and indicators.

� Confirm that the equipment, including all safety devices (guards,interlocks, etc.), is in good working order and that the requiredenvironmental conditions exist.

� Use the personal protective equipment (PPE) specified for each task.Refer to Equipment Safety Information or the material manufacturer’sinstructions and MSDS for PPE requirements.

� Do not use equipment that is malfunctioning or shows signs of apotential malfunction.



Maintenance and Repair Practices � Perform scheduled maintenance activities at the intervals described in

this document.

� Relieve system hydraulic and pneumatic pressure before servicing theequipment.

� De-energize the equipment and all auxiliary devices before servicing theequipment.

� Use only new factory-authorized refurbished or replacement parts.

� Read and comply with the manufacturer’s instructions and the MSDSsupplied with equipment cleaning compounds.

NOTE: MSDSs for cleaning compounds that are sold by Nordson areavailable at www.nordson.com or by calling your Nordsonrepresentative.

� Confirm the correct operation of all safety devices before placing theequipment back into operation.

� Dispose of waste cleaning compounds and residual process materialsaccording to governing regulations. Refer to the applicable MSDS orcontact the authority having jurisdiction for information.

� Keep equipment safety warning labels clean. Replace worn ordamaged labels.

Equipment Safety Information This equipment safety information is applicable to the following types ofNordson equipment:

� hot melt and cold adhesive application equipment and all relatedaccessories

� pattern controllers, timers, detection and verification systems, and allother optional process control devices

Equipment Shutdown To safely complete many of the procedures described in this document, theequipment must first be shut down. The level of shut down required variesby the type of equipment in use and the procedure being completed. If required, shut down instructions are specified at the start of theprocedure. The levels of shut down are:

Relieving System Hydraulic Pressure

Completely relieve system hydraulic pressure before breaking any hydraulicconnection or seal. Refer to the melter-specific product manual forinstructions on relieving system hydraulic pressure.



De-energizing the System

Isolate the system (melter, hoses, guns, and optional devices) from allpower sources before accessing any unprotected high-voltage wiring orconnection point.

1. Turn off the equipment and all auxiliary devices connected to theequipment (system).

2. To prevent the equipment from being accidentally energized, lock andtag the disconnect switch(es) or circuit breaker(s) that provide inputelectrical power to the equipment and optional devices.

NOTE: Government regulations and industry standards dictate specificrequirements for the isolation of hazardous energy sources. Refer tothe appropriate regulation or standard.

Disabling the Guns

All electrical or mechanical devices that provide an activation signal to theguns, gun solenoid valve(s), or the melter pump must be disabled beforework can be performed on or around a gun that is connected to apressurized system.

1. Turn off or disconnect the gun triggering device (pattern controller, timer,PLC, etc.).

2. Disconnect the input signal wiring to the gun solenoid valve(s).

3. Reduce the air pressure to the gun solenoid valve(s) to zero; thenrelieve the residual air pressure between the regulator and the gun.

General Safety Warnings and Cautions Table 1 contains the general safety warnings and cautions that apply toNordson hot melt and cold adhesive equipment. Review the table andcarefully read all of the warnings or cautions that apply to the type ofequipment described in this manual.

Equipment types are designated in Table 1 as follows:

HM = Hot melt (melters, hoses, guns, etc.)

PC = Process control

CA = Cold adhesive (dispensing pumps, pressurized container, andguns)



Table 1 General Safety Warnings and Cautions

EquipmentType Warning or Caution

HM

WARNING: Hazardous vapors! Before processing any polyurethanereactive (PUR) hot melt or solvent-based material through acompatible Nordson melter, read and comply with the material’sMSDS. Ensure that the material’s processing temperature andflashpoints will not be exceeded and that all requirements for safehandling, ventilation, first aid, and personal protective equipment aremet. Failure to comply with MSDS requirements can cause personalinjury, including death.

HM

WARNING: Reactive material! Never clean any aluminum componentor flush Nordson equipment with halogenated hydrocarbon fluids.Nordson melters and guns contain aluminum components that mayreact violently with halogenated hydrocarbons. The use ofhalogenated hydrocarbon compounds in Nordson equipment cancause personal injury, including death.

HM, CA

WARNING: System pressurized! Relieve system hydraulic pressurebefore breaking any hydraulic connection or seal. Failure to relievethe system hydraulic pressure can result in the uncontrolled release ofhot melt or cold adhesive, causing personal injury.

HM

WARNING: Molten material! Wear eye or face protection, clothingthat protects exposed skin, and heat-protective gloves when servicingequipment that contains molten hot melt. Even when solidified, hotmelt can still cause burns. Failure to wear appropriate personalprotective equipment can result in personal injury.

Continued...



General Safety Warnings and Cautions (contd)

Table 1 General Safety Warnings and Cautions (contd)


HM, PC

WARNING: Equipment starts automatically! Remote triggeringdevices are used to control automatic hot melt guns. Before workingon or near an operating gun, disable the gun’s triggering device andremove the air supply to the gun’s solenoid valve(s). Failure todisable the gun’s triggering device and remove the supply of air to thesolenoid valve(s) can result in personal injury.

HM, CA, PC

WARNING: Risk of electrocution! Even when switched off andelectrically isolated at the disconnect switch or circuit breaker, theequipment may still be connected to energized auxiliary devices.De-energize and electrically isolate all auxiliary devices beforeservicing the equipment. Failure to properly isolate electrical power toauxiliary equipment before servicing the equipment can result inpersonal injury, including death.

CA

WARNING: Risk of fire or explosion! Nordson cold adhesiveequipment is not rated for use in explosive environments and shouldnot be used with solvent-based adhesives that can create anexplosive atmosphere when processed. Refer to the MSDS for theadhesive to determine its processing characteristics and limitations.The use of incompatible solvent-based adhesives or the improperprocessing of solvent-based adhesives can result in personal injury,including death.

HM, CA, PC

WARNING: Allow only personnel with appropriate training andexperience to operate or service the equipment. The use of untrainedor inexperienced personnel to operate or service the equipment canresult in injury, including death, to themselves and others and candamage to the equipment.

Continued...




HM

CAUTION: Hot surfaces! Avoid contact with the hot metal surfacesof guns, hoses, and certain components of the melter. If contact cannot be avoided, wear heat-protective gloves and clothing whenworking around heated equipment. Failure to avoid contact with hotmetal surfaces can result in personal injury.

HM

CAUTION: Some Nordson melters are specifically designed toprocess polyurethane reactive (PUR) hot melt. Attempting to processPUR in equipment not specifically designed for this purpose candamage the equipment and cause premature reaction of the hot melt.If you are unsure of the equipment’s ability to process PUR, contactyour Nordson representative for assistance.

HM, CA

CAUTION: Before using any cleaning or flushing compound on or inthe equipment, read and comply with the manufacturer’s instructionsand the MSDS supplied with the compound. Some cleaningcompounds can react unpredictably with hot melt or cold adhesive,resulting in damage to the equipment.

HM

CAUTION: Nordson hot melt equipment is factory tested withNordson Type R fluid that contains polyester adipate plasticizer.Certain hot melt materials can react with Type R fluid and form a solidgum that can clog the equipment. Before using the equipment,confirm that the hot melt is compatible with Type R fluid.

Other Safety Precautions � Do not use an open flame to heat hot melt system components.

� Check high pressure hoses daily for signs of excessive wear, damage,or leaks.

� Never point a dispensing handgun at yourself or others.

� Suspend dispensing handguns by their proper suspension point.



First AidIf molten hot melt comes in contact with your skin:

1. Do NOT attempt to remove the molten hot melt from your skin.

2. Immediately soak the affected area in clean, cold water until the hot melthas cooled.

3. Do NOT attempt to remove the solidified hot melt from your skin.

4. In case of severe burns, treat for shock.

5. Seek expert medical attention immediately. Give the MSDS for the hotmelt to the medical personnel providing treatment.



Introduction

Description The LS10e Muller Martini Pre-Melter Hot Melt Unit is a light to medium dutymachine used for melting and pumping a variety of hot melt adhesives. Themelt unit consists of a heated melt tank and a motor−driven, positivedisplacement gear pump. The control panel and electrical enclosure aredesigned to IP22 water-resistant and dust−resistant standards. The meltunit is available in 4.5 kg (10 lb) tank capacity and supports 1 hose. Hosesare ordered separately from the melt unit and are covered by a separateproduct manual. When ordered as a system, hose is attached to the meltunit.

The melt unit is all-electric and accepts granular, flake or block forms ofadhesive. Tank temperature may be set from ambient to 232 °C (450 °F) byan adjustable thermostat controller.

Hose electrical connections are located under the melt unit just below thecontrol panel door. An adjustable thermostat controller controls hosetemperature.

4113039A

P OW ER

ON

OFF

PUMP OVERTE MPHE ATING

TANKTEM PERATURE

WARNING

Ifyoucanreadthis,thenyouaretoocloseandwilldamageyoureyes,younut!



Features � Resettable main circuit breaker on the control panel protects entire melt

unit from overload condition

� A tank overtemperature thermostat controls tank temperature in theevent of the primary tank controller failure.

� A pump warm-up thermostat protects the pump/drive mechanism bypreventing pump motor operation below safe temperature.

� A pump motor circuit breaker removes power from the pump motorcircuit in overload conditions.

� IP22 rated motor with automatically resettable thermal overloadprotection shuts off the motor in overload conditions.

� Fused hose heater circuit.

System Block Diagram

4113018A

MELT UNIT

LEGEND

HOSE

Motor GearPump

TerminalBlock

TemperatureController

Lights andControls

Electrical

TankHeater

Power Switch/CircuitBreaker

FluidMechanical

CUSTOMER−SUPPLIEDPOWER

Figure 1 System Block Diagram



Specifications

Electrical Voltage 230 VAC ±10% single phase

Power Requirements 900 W (melt unit only)

Fusing 2 PCB-mounted fuses

Main Circuit Breaker Rating 10 A

Frequency 50/60 Hz

Physical Tank Capacity 4.5 kg (10 lb)

Hose Capacity 1 hose

Shipping Weight 29.1 kg (64 lb)

Storage Temperature 0–60 °C (32–140 °F)

Pump Model and Size V4−675: 11.06 CCD (0.675 CID)

Performance Warm-up Time 30–45 minutes

Viscosity Maximum 25,000 centipoise (cps)

Melt Rate 3.6 kg/hr (8 lb/hr)

Environmental Ambient Air Temperature 5–40 °C (41–104 °F)

Altitude Sea level up to 2 km (1.24 miles)

Humidity 30–95 R.H. (%)

Motor Frequency 50/60Hz

Motor Speed 47/50 RPM



Installation

Setup 1. Remove all packaging material around melt unit.

2. Carefully lift melt unit out of box.

3. Unpack the binder containing product manuals, warranty informationand flow control valve hex wrench. Retain binder for future reference.

4. Unscrew 4 screws from plywood board base.

5. Carefully uncoil hoses from around melt unit. Inspect all packingmaterial for separately wrapped items.

6. Position melt unit for easy access to control panel and convenientservicing.

7. Level mounting surface to prevent warping of melt unit, and to avoidmisalignment of the pump and motor shaft.

8. Using the base mounting holes, bolt melt unit to a durable mountingsurface.

9. Tighten all screws before setup and after melt unit experiencesexcessive vibration.

Component Installation

Automatic System - Hoses Hoses are normally installed on an automatic melt unit at the factory with nouser installation required. If not installed, refer to Hose Replacement in theParts section. Refer to heated supply hoses product manual for completeinstallation and service information.



Electrical Circuits and Wiring

Power Requirements The LSe Muller Martini Pre-Melter Hot Melt Unit uses single phase 230 VACpower source with earth ground for safety. Ground fault protection must beprovided in supply circuitry at the site of installation. See Figure 2 below forterminal block configuration. An identification plate is attached to each meltunit on the outside rear panel of tank housing. This plate specifies melt unitvoltage and current as well as pump motor size, rpm and frequency. Forsafe and proper installation, refer to identification plate before applyingelectrical power to melt unit.

4113019A

L1 PEL2

servicesingle−phase

230/115 VAC L1/N/L2

N L1 PEL2

servicesingle−phase

200 −240 VAC L1/L2

Figure 2 Electrical Power Connection



This page intentionally left blank



Electrical Schematic and Motor Wiring Diagram Consult the schematic provided with the melt unit for all wire connections and component interconnections. Two schematics are shipped with each system: one with the product manuals; the other with the melt unit,either on or inside the rear panel. One copy of the schematic should remain with the melt unit at all times. The schematic below is for reference only.

L1 L2/N2−WIREL1−−200/240 VOLTS−−L2/N

M

CB1

FOR CUSTOMERINTERFACE.

1

2

3

4

NOTES:

FOR 230VAC WITH L2 DISCONNECT SOLID WIRE ON TERMINAL 20A TO 20 ( BY OEM ).

ATTACH WIRE NUMBERS AT BOTHENDS OF EACH WIRE.

TA TAPE

1

2

TANKFRT PNLMOTOR

40

1

2

3

4

5

6

4132

39

1

3 4

2

1

2

1 21A

F2

(150W)HOSE HTR

1 2

ADJUSTABLE

TS11 2

W1 2

LMP1

G1 2

LMP3

R1 2

LMP2

400 F

TS2

1 2(400W)HTR1

1 2

(400W)HTR2

1 2

250 F

TS31 21 2 3 4

1 21A

F1

300−400

TS41 2

CB2 CB2 (TYPICAL 6’ HOSE)

1

6

19

313027

32

43

42

47

4215

14

18

13

17

5

10 12

16

22 23 24

36 37 38

33

3444 45 46 47

38

11

28 29

2

11

9B 8

20 20A

9A9

10

1

J1

REDBLU

BLK

(10A)

(1A)

(PART OF CB1)

R1

(100K)

MULLTER MARTINI LS10Figure 3 Schematic



Electrical Connections

CAUTION: Power cords must be approved by a harmonized (HAR) agencyand rated for 75 5C (167 5F). A HAR approved Type B plug and strain relieffor power cord are required to meet standard IEC 309. Power conductingwires must be nominal 5.3 mm2 (10 AWG) maximum and nominal 2.1 mm2(14 AWG) minimum. See Appendix A for a list of harmonized approvalagencies.

1. Inspect melt unit identification plate and inside electrical panel to verifyactual capacity and type of 230 VAC power plug required for the system.

2. Open front door and control panel.

3. Install appropriate power-in nominal 2.1 mm2 (14 AWG) wires in theterminal blocks TP and grounding terminal PE provided. See Figure 2.Conduit fittings are recommended when routing wires to electricalterminal blocks. A hole in the chassis is provided for this installation.

4. Route power cord to avoid contact with pump or flow control block dueto high temperatures.

5. Close front control panel after electrical hookup.

External Control of Pump Motor for Automatic Systems The pump motor circuit may be connected to a parent machine or othercontrol device to enable the parent machine to control the hot melt systempump. This extends pump life and provides added safety when the melt unitis used in conjunction with other machinery.

1. Using melt unit schematic, locate parent machine or pump lockoutjumper.

2. Remove parent machine/pump lock-out jumper.

3. Wire contacts from external device to the melt unit main terminal blockwhere the parent machine/pump lock-out jumper was located.



Operation

Controls and Indicators Read this section carefully before operating melt unit. See Figure 4.

System Power Switch/Circuit Breaker/Power ONIndicator Controls power to system and all components receiving power from meltunit. This switch is also the main circuit breaker for the system and trips, oropens, if an overload or short occurs. Switch illuminates when melt unit ispowered ON.

Tank Over-temperature Indicator The melt unit contains a bimetallic fixed thermostat which providesover-temperature protection for the melt tank. This thermostat is locatedinside the rear of the melt unit on or near the tank base. Should the normaltank controller fail, the tank temperature will increase to the rating of thisthermostat. The red warning light will illuminate. This thermostat controls thetank heaters until the normal tank controller is repaired. Refer to TankTemperature Controller Replacement in the Repair and ReplacementSection and to the Troubleshooting Section.

Tank Temperature Gauge Indicates the temperature of hot melt material in the melt tank. The HoseTemperature Adjustment, located behind the front panel, indicates thetemperature of the material in the hose.

NOTE: The following two controls are located inside the electricalenclosure and require a trained maintenance technician to adjust. Refer toTemperaturel Adjustments, for instructions.

Tank Temperature Controller (not shown) A full-range adjustable bimetallic thermostat sets and controls tanktemperature. Located on the front of the melt tank base, it is accessible atthe small access panel inside the electrical enclosure. Adjustments requirea flat blade screwdriver. Refer to Temperature Adjustments.



Hose Temperature Controller (not shown) An adjustable thermostat capillary controller sets and controls hosetemperature. Located on the electrical panel inside the electrical enclosure,the controller is attached to a capillary bulb sensor located in the hose.Refer to Temperature Adjustments.

Tank Heating Indicator Illuminates green when tank heaters are powered and assists user inmaking temperature adjustments to tank temperature controller.

Pump Motor Switch/Circuit Breaker This switch powers the pump motor for normal operation. The switch stopspower to the pump motor during periods of inactivity or systemmaintenance. A circuit breaker in the switch protects the motor during a stallor overload condition. Two additional circuits protect the pump and motor:

Pump Warm-up Thermostat

The pump warm-up thermostat prevents the pump motor from startingbefore system reaches operating temperature. This thermostat is located onthe back of the tank inside the rear panel of the melt unit. The thermostattemperature rating is specified based on the adhesive and the application.

Motor Thermal Overload Protection

The motor thermal overload protection prevents the motor from overheating.The motor stops when overheated and begins operating again when thetemperature drops to a level.

4113020A

TANK

ON

OFF

PUMP

POWER

HEATING

TEMPERATURE

OVERTEMP

1

4

5

3

2

W ARNING


Figure 4 Motor Display Panel

1. Power switch2. Over-temperature indicator light3. Tank temperature indicator

4. Heating indicator5. Pump on/off switch



Startup

WARNING: Allow only personnel with appropriate training and experienceto operate or service the equipment. The use of untrained or inexperiencedpersonnel to operate or service the equipment can result in injury, includingdeath, to themselves and others, and damage to the equipment.

WARNING: To avoid personal injury, follow all safety labels. Failure toproperly operate and maintain equipment can lead to serious injury.

WARNING: Wear protective clothing, safety goggles and safety gloves.Hot melt materials can cause severe burns resulting in disfigurement orblindness.

WARNING: Disconnect electrical power from external source to melterbefore undertaking maintenance or troubleshooting. Failure to disconnectpower can result in fatal electrical shock.

WARNING: Depressurize the system before performing any maintenanceto the pump, pump filter, flow control valve, or hose. Turn the pump switchoff and depress the trigger on the handgun until there is no flow. Air trappedin the system or in a component can form a pressure pocket. Loosenfittings cautiously. Adhesive under pressure can cause severe burns andblindness.

CAUTION: Use only manufacturer recommended materials in this system.Fire, explosion, personal injury, property and equipment damage can resultif improper or unsafe materials are us



General 1. Become familiar with Controls and Indicators.

2. Install melt unit as specified in Setup in the Installation section.

3. Fill tank with hot melt to 3.8 cm (1.50 in.) from top.

4. Power on melt unit and allow 30–45 minutes warm-up time.

5. Align motor, if necessary. Motor alignment is necessary on receipt of anew melt unit; after transportation; when replacing the motor,pump-shaft, bearing block or pump; or when the motor is noisy. Alignmotor as follows:

a. Loosen but do not remove 4 screws holding the motor.

b. Warm-up melt unit and run motor. This centers the motor.

c. With motor running, tighten 4 button screws in a crisscross pattern.

d. Check coupler gaps − refer to Pump Replacement in the Repair andReplacement section.

6. Set hose and tank temperature to desired settings. Lower settingsincrease material life. Refer to Temperature Adjustments.

7. Set tank temperature as low as possible for each application. Certainmaterials degrade over time due to oxidation.



Temperature Adjustments

WARNING: Disconnect power at external source before opening frontcontrol panel. Hazardous voltage can shock, burn or cause death.

Tank Temperature Controller 1. To prevent hot melt degradation, set melt tank temperature to the

minimum temperature specified by the hot melt manufacturer.

2. Open front control panel.

3. See Figure 5. To raise melt tank temperature, rotate tank temperaturecontroller adjustment shaft (1) clockwise with screwdriver.

To lower melt tank temperature, rotate adjustment shaft (1)counter-clockwise with screwdriver. The melt tank temperature controllerranges 260 °C (500 °F) in one 320° rotation of the adjustment shaft.

4. Verify temperature on tank temperature meter.

5. Allow tank temperature to stabilize 30 minutes before adjusting further.

4113021A1

Figure 5 Tank Temperature Controller

1. Adjusting shaft



Hose Temperature Controller Temperature graduations on hose controller reflect approximate hosetemperature.

1. Measure inside hose temperature with a pyrometer and bead probe.Hose temperature should be the minimum temperature required forapplication to prevent degradation of material in the hose and maximizehose life.

2. Open front control panel.

3. See Figure 6. To raise hose temperature, rotate knob (1) clockwise todesired temperature.

To lower hose temperature, rotate knob (1) counter-clockwise to desiredtemperature.

4. Refer to Temperature Check in the Maintenance Section of the HeatedSupply Hose Manual.

4113022A

Figure 6 Hose Temperature Controller

1. Adjusting knob



Maintenance WARNING: Allow only personnel with appropriate training and experienceto operate or service the equipment. The use of untrained or inexperiencedpersonnel to operate or service the equipment can result in injury, includingdeath, to themselves and others, and damage to the equipment.

WARNING: Wear protective clothing, safety goggles and safety gloves.

WARNING: Depressurize system. Place pump motor switch in off position.Activate applicator trigger or valve until pressure is released and noadhesive flows. Discontinue system power.

WARNING: Disconnect electrical power at external source.

WARNING: Allow equipment to cool before servicing.

CAUTION: To prevent damage to components (hose fittings, etc.), heatpart(s) being serviced to approximately 121 5C (250 5F) prior todismantling, assembly or adjustment. Heat parts by applying power to meltunit, using a hand held hot air gun or placing parts on a hot plate. Failure todo this will result in stripped threads and ruined parts and tools.

CAUTION: To avoid arcing of electrical contacts and possible failure ofcomponents, disconnect power to hoses before joining electricalconnectors.



Preventive Maintenance

Procedure Daily Monthly As Required*

Check for foreign material in tank. X

Wipe off excess hot melt from cover. X

Check for leaks. X

Purge tank and hoses. X X

Inspect hoses. X

Check tank temperature. X

� Hoses: Verify that hose is properly supported so it is not stressed duringuse. Minimum bend radius is 20 cm (8 in.). See appropriate hosemanual for complete hose care guidelines. Adjust temperatureaccording to Temperature Adjustments in the Operation section. Onmulti-hose systems, a temperature difference between hoses may bedetected by touching outer insulation of each hose.

� Tank: Verify that system is not operating in overtemperature mode byobserving Overtemperature Indicator Light. Determine tank temperatureand adjust according to Temperature Adjustments in the Operationsection.



Troubleshooting

Problem Corrective Action

1. Tank Does Not Heat If tank OVERTEMP indicator is illuminated on startup at ambienttemperature, replace tank overtemperature thermostat.

Measure power to incoming side of main circuit breaker and/orpower switch with voltmeter. If inadequate voltage, check sourcepower supply and incoming wiring.

With power switch and main circuit breaker on, check voltage onoutput side of switch and breaker. If no voltage, replace powerswitch/circuit breaker.

With power source off, use schematic to ensure that all wires totank controller and heaters are properly terminated and in goodcondition.

Check tank controller voltage output. If no output, replace tankcontroller.

Measure resistance of each tank heater. Compare resistancewith Component Resistance Tables in Appendix B. Replaceheaters if faulty.

2. Tank Heats Slowly Measure source voltage to ensure that it matches melt unitrating. Low voltage results in slow heating of all systemcomponents.

If tank heats but never reaches desired temperature, raisetemperature setting at the controller in small increments.

Measure resistance of each tank heater. Compare resistancewith Component Resistance Tables in Appendix B. Failure of anytank heater can result in slow heating. Replace tank heater(s), ifnecessary.

3. Tank OVERTEMP Indicator Is Lit If tank OVERTEMP indicator is illuminated on startup at ambienttemperature, replace tank overtemperature thermostat.

With system at operating temperature, measure tanktemperature when OVERTEMP indicator is lit. If actualtemperature is too high, turn tank controller counter clockwise toreduce temperature.

If controller does not adjust tank temperature, turn system poweroff and replace tank controller.

If indicator is lit when tank reaches desired temperature, eitherthe thermostat is faulty or rated too low. Replace tankover-temperature thermostat with thermostat of correcttemperature rating.

Continued...

4113023A

987

654

321



Corrective ActionProblem

4. Hose Heats Slowly Measure source voltage to ensure that it matches melt unitrating. Low voltage results in slow heating of all systemcomponents.

Check all wire connections in hose heater circuit. Tighten ifneeded.

Check hose heater resistance.

� Turn power off and disconnect hose electrical connectorfrom melt unit.

� See Figure below for correct pin locations.

� Measure resistance of hose heater.

� Compare resistance with Component Resistance Tablesin Appendix B.

� If hose heater is faulty, replace hose.

If hose heats but never reaches desired temperature, raisetemperature at the controller in small increments.

Thermostat Hose – Male Connector Pin Location andFunction

Table 1 OP Automatic Hose

Pin Function

1 Ground

2 Heater Circuit Return

3 blank

4 blank

5 blank

6 Hose Heater (with Pin no.2)

7 blank

8 blank

9 blank

Figure 7 Thermostat Hose MaleConnector PinLocations



Problem Corrective Action

1. Hose Fails to Heat Measure voltage from power switch to hose controller. If novoltage, ensure that all connections are secure.

Ensure that voltage is present between hose controller and hoseheaters. If no voltage, replace hose controller.

Ensure that all pins are seated properly and in the correctlocation.

Locate pins for hose heating element and check resistance.Refer to hose manual and Component Resistance Tables inAppendix B. If hose heater is defective, replace hose.

Ensure that all pins are seated properly and in the correctlocation.

� Turn power off and disconnect hose electrical connectorfrom melt unit.

� Check electrical connector on input end of hose.

� Reseat or relocate pins if needed.

2. Hose Is Too Hot Lower temperature by turning hose controller adjustmentcounter-clockwise.

Check capillary bulb sensor for proper insertion into hose cuff.Refer to Hose Replacement in the Repair and Replacementsection.

Check capillary tube to ensure it is not broken or kinked. Ifcapillary tube is damaged, replace hose controller.

3. Motor Fails to Function WhenP S i h I A i d

Ensure that system power is on and indicator in switch is lit.Pump Switch Is Activated Check for presence of jumper between TA-9 and TA-9A. When

this jumper is removed, parent machine has control of motorstart.

Check voltage to pump motor switch and output from switch.This switch is also a circuit protection (breaker) device. If switchtrips repeatedly, check for shorts in the motor wiring circuit. Ifpump motor switch is faulty, replace. Also check the circuitbreaker as explained in the first procedure on the next page.

If melt unit is at desired operating temperature, inspect pumpwarm-up thermostat inside rear panel. If thermostat has failed orif lower temperature rating is needed, replace warm-upthermostat.

Continued...



Corrective ActionProblem

3. Motor Fails to Function WhenPump Switch Is Activated contd.

If melt unit was operating when problem occurred, determinewhether circuit breaker in the pump motor switch has tripped. Ifyes, reset pump motor switch and observe. If breaker trippingcontinues:

� Check for other possible cause of overload such asobstruction in pump inlet. Remove any obstruction andreset pump motor switch.

If melt unit was operating when problem occurred, an overloadcondition could have overheated the motor resulting in activationof thermal overload protection within the motor.

� Turn off pump motor switch, wait until motor cools andrestart motor.

� Once restarted, ensure that motor fan is functioning bycarefully checking for positive air flow below the motorfan housing.

� Replace motor if necessary.

4. Motor Runs But No AdhesiveOutput

Ensure that motor rotation is counter clockwise when viewedfrom top of motor.

If problem arises on start up, check for correct wiring in motorjunction box. Check for reversed wires. Refer to schematiclocated in rear of melt unitand Figure 3.

If motor direction reverses after period of normal operation,replace motor start/run capacitor.

NOTE: If troubleshooting attempts fail, contact your factory representative.



Repair and Replacement See Parts List, for all replacement parts listed in this section.

CAUTION: For safe and proper hose replacement verify that all material inmelt tank has completely solidified.

Hose Replacement

Removing the Hose 1. Place system power in off position and allow hot melt in tank to

completely solidify.

2. Place system power in on position for 5 minutes to allow fittings to warmor heat fitting with a hand-held hot air gun.

3. Place system power in off position and disconnect melt unit electricalpower from external source.

4. See Figure 8. Disconnect hose electrical connector.

5. Tilt melt unit backwards until underside is accessible. Support melt unitwith block on back of housing so adhesive does not spill. Do not turnmelt unit upside down.

6. Remove screws from hose mounting block (2).

7. Loosen hose JIC fitting and remove hose (1) from the fitting (3) on thehose manifold block.

8. Carefully remove capillary bulb sensor (4) from hose.

4113024A

3

2

1

4

MM001

Figure 8 Hose Connections

1. Hose2. Hose mounting block

3. Hose manifold block fitting4. Capillary bulb sensor



Replacing the Hose 1. Place system power in off position and disconnect melt unit electrical

power from external source.

2. Never flex a hose when cold. Hoses have a minimum bend radius of20.32 cm (8 in.) when hot. Further flexing will cause permanent damage.

3. See Figure 9. Heat hose JIC fittings (5) before adjusting or damage mayresult. New or clean hose fittings may not require heating.

4. Install hoses on melt unit by tilting melt unit back until underside isaccessible. Support unit with block on back of housing so hot melt doesnot spill. Do not turn melt unit upside down.

5. Support hose to prevent excessive flexing. Ensure that hose supportdoes not add to its thermal insulating characteristics or overheating willresult. Failure to properly support the hose will result in prematurefailure.

6. Hose installation. See Figure 9.

a. Carefully insert capillary bulb sensor (4) into brass tube in end ofhose (1) and do not bend capillary tube (8) at a sharp angle.Thermostat hoses perform best when capillary bulb sensor ispositioned at 3 or 9 o’clock. Before final tightening, rotate hose onJIC fitting to obtain recommended position.

b. Loosely connect the hose JIC swivel fitting (5) to a straight or rightangle fitting (6) on the hose manifold block (7).

c. Fasten hose support block (3) to chassis.

d. Attach hose electrical connector (2).

e. Tuck capillary tubing (8) and electrical connector (2) under melt unit.

f. Position and support hose before using.

g. Tighten JIC swivel fittings (5).

h. Check all hydraulic fittings for tightness before pressurizing systemand retighten when hot. Check all electrical connections forcontinuity.

i. Retighten hydraulic fitting after unit has reached operatingtemperature.

4113025A4

67

5 2

31

8

Figure 9 Hose components

1. Hose2. Electrical connector3. Hose support block

4. Capillary bulb sensor5. JIC fittings6. Right angle fitting

7. Hose manifold block8. Capillary tube



Hose Temperature Controller Replacement 1. Perform Steps 1–8 of Hose Replacement to remove capillary tube and

bulb sensor from hose.

2. See Figure 10. Disconnect 3 wires on hose controller (3). Removeaccess panel (5) at bottom of electrical panel (4).

3. Remove 2 screws fastening controller to electrical panel (4). Carefullyremove capillary tube and bulb sensor (2).

4. Install new controller to electrical panel with 2 screws. Reconnect wiresto controller.

5. Insert capillary tube and bulb sensor from new controller throughchassis and into hose end at 3 or 9 o’clock position. Replace accesspanel (5).

6. Coil capillary tube so it hangs in a suitable position under chassis.

7. Reconnect melt unit power, turn on power switch, and adjust controlleras specified in Section 5.3: Temperature Adjustments.

8. If hose fitting disconnected, retighten fitting when heated.

4113026A1

2

43

5

Figure 10 Hose Temperature controller

1. Tank thermostat controller2. Bulb sensor3. Hose controller

4. Electrical panel5. Access panel



Tank Temperature Controller Replacement 1. Disconnect melt unit electrical power from external source.

2. Open front door and control panel. See Figure 11.

3. Remove tank access panel (5) at bottom of electrical panel (4).

4. Remove wires connected to thermostat at terminal. Tank thermostatcontroller (1) is mounted horizontally on tank base plate.

5. Remove 2 screws holding tank thermostat to clean tank base plate.

6. Apply even coating of heat sink compound to base of new thermostat.

7. Attach replacement thermostat to tank base. Reconnect wires.

8. Replace tank access panel (5).

WARNING: Failure to replace access panel will create an electrical hazardand possible heat damage to electrical components.

9. Close front control panel.

4113027A1

2

43

5

Figure 11 Tank Temperature Controller

1. Tank thermostat controller2. Bulb sensor3. Hose controller

4. Electrical panel5. Access panel



Tank Heater Replacement 1. Before considering replacement, check heaters with amp probe (system

power on) or ohmmeter (system power off, wires disconnected).Determine resistance of each individual heater. Refer to schematiclocated in the rear of the melt unit and diagram in the Installationsection.

2. Switch off system power and disconnect electrical power from externalsource.

3. Open front door, control panel and remove tank access panel (2). SeeFigure 12.

4. Determine resistance of each individual heater (1).

5. Disconnect wires on defective heater.

6. Pull heater out of bore using pliers. If heater does not come out easily,drive out using a 6.35 mm (0.25 in.) diameter rod inserted in knockoutholes in back of tank base.

7. Apply a coating of heat transfer paste to new heater and slide it into tankheater bore from the front.

8. Route heater lead wires through electrical panel and reconnect heaterwires in original locations. Refer to schematic located in rear of melt unitand diagram in the Installation Section.

9. Replace tank access panel.

10. Close and fasten control panel and door.

4113028A

1

2

Figure 12 Tank Heaters

1. Tank access panel 2. Heater

4113029A

21



Tank Over-temperature Thermostat Replacement

WARNING: The overtemperature thermostat is a necessary safety devicefor preventing runaway heating on all melt units. Do not bypass thisprotection. Runaway heating of tank can cause hot melt materials to burstinto flames.

1. Disconnect melt unit electrical power at external source.

2. Open rear access panel.

3. Locate over-temperature thermostat (2). See Figure 13.

4. Remove mounting screws and wire connectors from over-temperaturethermostat.

5. Remove thermostat and clean mounting surface.

6. Apply a small amount of heat transfer paste on back side of replacementover-temperature thermostat.

7. Position thermostat in appropriate location on tank base and attachusing mounting screws.

8. Reconnect over-temperature thermostat wire connectors and replacerear panel.

Figure 13 TankOver-temperatureThermostats

1. Pump warm-up thermostat2. Over-temperature thermostat

4113029A21



Pump warm-up Thermostat Replacement 1. Disconnect melt unit electrical power at external source.

2. Open rear access panel.

3. See Figure 14. Locate pump warm-up thermostat (1). Remove tankinsulation as needed.

4. See Figure 15. Cut plastic wire ties holding insulation sleeving (3) inplace.

5. Slide sleeving (3) toward tank to expose butt connectors (2), and cutwires as close to connectors as possible.

6. Remove mounting screws and thermostat. Clean mounting surface.

7. Apply heat transfer paste to new thermostat, and install thermostat ontank or tank base.

8. Install new pump warm-up thermostat.

9. Strip wires to approximately 6 mm (0.25 in.).

10. Ensure sleeving (3) is in place on wires. Crimp wires to new thermostat.

11. Reposition sleeving over butt splices and secure with wire ties.

12. Replace tank insulation, as needed.

13. Replace rear access panel.

Figure 14 Pump Warm-upThermostat

1. Pump warm-up thermostat2. Over-temperature thermostat

4113030A

12

3

Figure 15 Thermostat Replacement

1. Over-temperature thermostat2. Butt connectors

3. Wire ties

4113031A

1

4

3

2

5

8, 9, 10

6

7



V4 Pump Replacement 1. If melt unit is cold, allow it to heat approximately 5 minutes.

2. Depressurize system by manually activating applicator(s).

3. Remove electric power from system at main circuit breaker and atexternal source.

4. Disconnect hose electrical connection from bottom of control box.

5. Remove 4 screws (8), 4 lock washers (9) and 4 flat washers (10) holdingpump block (6) (with hose attached) and pump assembly (3 and 4).Retain screws and washers (8, 9, 10) for reassembly.

6. Remove pump block (6), leaving hose attached, and set aside.

7. Remove and discard existing pump assembly (3 and 4) and gasket (1).

8. Coat wear plate o-ring (5) with silicone lubricant.

9. Insert wear plate o-ring (5) into groove in wear plate (4).

10. Place new pump assembly (3 and 4) onto pump block (6).

11. Place new gasket (1) onto new pump assembly (3 and 4). No sealantsare necessary.

12. Align tab (2) on end of pump with slotted end of pump shaft assembly.

13. Tighten existing 4 screws (8), 4 lock washers (9) and 4 flat washers (10)(note Step 5) in a crisscross fashion.

14. Reconnect hose electrical connections.

Figure 16 V4 Pump

1. Gasket2. Tab3. Pump4. Pump wear plate5. Wear plate o-ring6. Pump block7. Elbow8. Screws9. Lock washers

10. Flat washers

15. Restore power to melt unit.

16. With pump switch off, allow melt unit to heat to operating temperature.

17. Retighten pump screws (8) to 5.65−8.47 N�m (50−75 lb-in.).

18. Test melt unit and adjust pressure.

19. Check for leaks.

20. Return melt unit to service.



Pump Motor and Pump Shaft Assembly Replacement 1. Disconnect electrical power and allow melt unit to cool to

121 °C (250 °F).

2. Open motor junction box cover (1), disconnect wiring and conduit fitting(2). See Figure 17.

3. Remove screws (4) holding motor mounting plate (13) to melt unit.

4. Lift motor assembly and motor mounting plate off melt unit.

5. Inspect motor shaft coupler (3) for wear. Replace if necessary.

6. If replacing pump shaft assembly, or individual shaft assembly parts,remove bronze spider (6), coupler and key (10 and 11), washer (7), andshaft (8) with shaft retaining spring (9). If not replacing shaft assembly,skip to Step 8.

7. Install new shaft assembly or individual components as needed.

8. Remove screws (5) holding pump motor to motor mounting plate (13).

9. Install new pump motor on motor mounting plate.

10. Check pump shaft alignment on pump in tank.

11. Align motor coupling (3) with pump shaft in tank and lower onto shaft.

12. Align motor mounting plate to melt unit with mounting screws (4).

13. Verify that pump shaft seats properly with pump and verify couplerclearance of 0.8 mm ±0.3 mm (0.030 in. +0.010, -0.000 in.).

14. Replace conduit fitting and wires (2).

15. Reconnect wires according to schematic, located in the rear of the meltunit and diagram in Section 4.3. Refer to melt unit identification plate todetermine exact voltage.

16. Turn melt unit on and allow melt unit to heat to normal operatingtemperature. Turn pump motor on.

17. Tighten screws (4) in a crisscross pattern while motor is operating toalign pump shaft.

18. If replacing complete motor group, also replace pump motor switch onfront panel and motor capacitor inside electrical enclosure.



4113032A

12

6

1

4

3

2

5

7

8

10, 11

9

4

0.8mm[−0, +0.3mm]

[−0, +0.010 in.]0.030 in.

Figure 17 Pump Motor and Shaft Assembly

1. Motor junction box cover2. Conduit fitting3. Motor shaft coupler4. Motor mounting plate screws

5. Pump motor screws6. Spider7. Washer8. Shaft

9. Shaft retaining spring10. Coupler11. Key12. Motor mounting plate



Fuse Replacement NOTE: Note: Both fuses are present on all machines. On 230 VAC (L1/N),Fuse 2 is bypassed. Refer to schematic located in rear of melt unit andFigure 3.

1. Switch off system power at main circuit breaker and disconnect melt unitpower.

2. Open front door (control panel) and locate main terminal block and fuselocations.

3. See Figure 18 for fuse location. Lightly press down on top of fuse holder(3). This causes the fuse holder to pivot down and out towards thetechnician.

4. Lift hinged plastic cover (1) protecting fuse. Remove fuse (2).

5. If fuse is not visibly damaged, check continuity with an ohmmeter. Cleancontact points in fuse holder as necessary. If replacement is necessary,refer to parts list or schematic for correct fuse rating.

6. Replace new fuse in fuse holder. Place fuse holder back in place andverify it is seated firmly.

7. Close and secure control panel door.

8. Return melt unit to operation.

4113032A

Hose 1

1 2

3

Figure 18 Fuse Locations

1. Plastic cover2. Fuse

3. Fuse holder



Parts List

Main Systems Components Item Description (Quantity) MM Part

NumberNordson Part

Number

LS10, 240V, CE (IP22) W/6 ft Op Hs 1030410

Hose #6 240V 450 F 6 ft P−450, 20 in. 1530.5878.4 1014196

Recommended Spares Item Description (Quantity) MM Part

NumberNordson Part

Number

Tank

HTR1, 2 Heater, tank, 230V, 400 W (uses 2) 1530.1673.4 1028259

TS2 Over-temperature switch, 205°C (400°F) 1570.1675.4 1019556

TS1 Tank controller, 100–450 °F 1530.5899.4 1030410

Thermostat

TS3 Thermostat, pump warm-up 1530.5900.4 1030407

TS4 Thermostat, hose controller 1530.5868.4 1030505

Motor

Motor assy, 47R/50H, LS10 spell 1570.1821.4 1027132

Coupler, L-070, 1/2 in., 1/8 in. keyway 1570.1822.4 1029300

Coupler, L-070, 11 mm bore, 4 mm key 1570.1823.4 1029300

Spider, #L-070; Bronze, open ctr 1530.5907.4 1029293

Pump shaft 1570.1824.4 1030438

Retaining spring, pump shaft 1570.1825.4 1032624

Pump

Pump and seal replacement, V4-675 1570.1826.4 1032186

O-Ring, PTFE, 0.070 in. W X 0.614 in. ID 1570.1828.4 1031304

O-Ring, PTFE, V4 pump 1530.5904.4 1029238

Gasket, pump to tank 1530.5901.4 1031284

Breakers

CB1 Breaker, 10 amp,240V, 2 pole 1033979

CB2 Breaker, 1.0 amp, 250V, 2 pole 1033995

Fuse

F1,F2 Hose: 1 amp, slo blo, 5X20 mm 1570.1830.4 939965



Control Panel Item Description (Quantity) MM Part

NumberNordson Part

Number

1 CB1 Breaker, 10.0 amp, 250 V, 2 pole 1033979

2 PL2 Lamp, round, 250V, lt red 1030383

3 Thermometer with case 1028178

4 PL3 Lamp, round, green, 250V 1030385

5 Breaker, 1.0 amp, 250V, 2 pole 1033995

4113020A

TANK

ON

OFF

PUMP

POWER

HEATING

TEMPERATURE

OVERTEMP

1

4

5

3

2

WARNING


Figure 19 Control Panel



Hose Item Description (Quantity) MM Part

NumberNordson Part

Number

1 Hose #6, 24V 450f 6 ft P−450, 20 in. 1530.5878.4 1014196

2 TS4 Thermostat, hose control ,300–400 °F 1530.5895.4 1030505

3 Male L. elbow 3/8 in. pipe 3/8 in. 1039385

4113034A

1

3

2

2

Figure 20 Hose Parts



Hose and Tank Temperature Controllers and Tank Heaters Item Description (Quantity) MM Part

NumberNordson Part

Number

1 TS1 Tank controller, 100–450 °F 1530.5899.4 1030410

2 HTR1,2 Tank heater 230 VAC, 400W (uses 2) 1570.1673.4 1028259

3 TS4 Thermostat, hose control, 300–400 °F 1530.5891.4 1030505

4 Panel, access LS10/20

4113035A

1

4

3

4

2

1

2

Figure 21 Hose and Tank Temperature Controllers and Tank heaters



Tank Over-temperature and Pump Warm-up Thermostat Item Description (Quantity) MM Part

NumberNordson Part

Number

1 TS3 Thermostat, pump warm-up, 121 °C (250 °F) 1530.5889.4 1030407

2 TS2 Over-temperature switch, tank, 205 °C (400 °F) 1570.1675.4 1019556

4113029A

21

Figure 22 Tank Over-Temperature and Pump Warm-up Thermostats



Motor Assembly Item Description (Quantity) MM Part

NumberNordson Part

Number

1 CB2 Breaker, 1.0 amp, 250 V, 2 pole 1033995

2 Wire nut ”Blue” #20-18 awg

3 Screw, shc; 8-32 X 3/8 in. lg

4 Screw, shc; 10-32 X 1 3/4 in.lg

5 Screw, socket head 6-32 X 3/16 in.

6 Washer, lock #6 split, plated

7 Washer, #8 split lock

8 Washer

9 Washer, #10 flat

10 Spacer, Al, #10 X 0.50 in. X 1.25 in. lg

11 Key, machine, 1/8 in. sq X 0.50 in.lg 1031328

12 Key, 4 mm sq X 18 mm lg 1033976

13 Knob, flat handle 1029285

14 Washer, 2.00 OD X 0.530 ID x 0.063 thk

15 Capacitor, motor, 5 uf +/−10%, VDE 1030419

16 Cap, terminal, capacitor 1031352

17 Motor, 230V, 47 rpm, 50 Hz, 1/15 hp 1027132

18 Mod., coupling, jaw, L-070, Lovjoy 1570.1822.4 1029294

19 Coupler, L070, 11 mm bore, 4 mm key 1570.1823.4 1029300

20 Spider, #L070; bronze−−open ctr 1530.5907.4 1030437

21 Lid plate

22 Label, system data plate

23 Retaining spring pump shaft 1570.1825.4 1032941

24 Seal plate, pump shaft, LS10H

25 Label, hot surface, 11/16 x 13/16 in.

26 Pump shaft, w/keyway,10# spcl 1570.1824.4 1033970

27 Lid assembly, LS Series Ii

28 Conduit assy, motor KB/FS/HF



4113036A

25 (2X)

22 (REF)

.030.010,(+ 0)−

16

15

1

5, 6 (4X)24

3, 7 (2X)

13

2127

23

14

26

4, 8, 9 (4X)

10 (4X)

11, 18

12, 19

20

28

17

22

2 (5X)

Figure 23 Motor Assembly



V4 Pump Item Description (Quantity) MM Part

NumberNordson Part

Number

1–5 Pump & Seal replacement,V4-.675 1570.1826.4 1032186

1 Gasket, pump to tank 1530.5901.4 1031284

2,3,4 Pump assy, V4-675 1031422

NS O-ring, V4 Pump 1530.5904.4 1029238

5 O-ring, PTFE, 0.070w X .614 in. ID 1570.1828.4 1031304

6 Plate, pump, V4 1031372

7 Male elbow, tube 3/8 in., pipe 3/8 in. 973137

8 Screw, SHC; 1/4-20 X 2-1/4 in.long

9 Washer, lock 1/4 in. ID

10 Washer, R.O.D., 1/4 in. zinc

4113031A

1

4

3

2

5

8, 9, 10

6

7

Figure 24 V4 Pump



Pump Shaft Assembly Item Description (Quantity) MM Part

NumberNordson Part

Number

6 Spider, #L070; bronze−−open ctr 1530.5907.4 1030437

7 Washer, 2.00 in. OD X 0.530 in. ID X 0.063 thick

8 Pump shaft, w/keyway, 10# spcl 1570.1824.4 1033970

9 Retaining spring pump shaft 1570.1825.4 1032941

10 Coupler, L-070, 1/2 in., 1/8” keyway 1570.1822.4 1029300

11 Key, machine, 1/8 in. sq X 0.50 in. Lg 1031328

4113037A

6

7

8

10, 11

9

Figure 25 Pump Shaft Assembly

Fuses Item Description (Quantity) MM Part

NumberNordson Part

Number

1 F1,F2 Fuse, 1 Amp, Slo-Blo, 5X20 mm 1570.1830.4 939965

4113038A

Hose 1

Figure 26 Location of Fuses

Harmonized Approval Agencies A-1


Appendix AHarmonized Approval Agencies

Country Authorizing Body

U.S.A. UL Recognized

Canada Canadian Standards Association

Germany TÜV

United Kingdom BEAB − British Electrotechnical Approvals Board

France Union Technique de L’Électricité

Sweden SEMKO − Svenska ElektriskaMaterielkontrollanstalten

Norway NEMKO − Norges Electriske Materielkontroll

Denmark DEMKO- − Danmarks Electriske Materiallkontrol

Netherlands KEMA-N.V. Tot Keuring van ElectrotechnischeMaterialen

Finland Sahkotarkastuslaitos Ry Electriska Inspektoratet RF

Switzerland Schweizerischer Electrotechnischer Verein

Austria Österreichischer Verband für Elektrotechnik

Italy IMQ Instituto Italiano del Marchio di Qualità

Japan JETL-Japan Electrical Testing Laboratories

Harmonized Approval AgenciesA-2


Component Resistance Tables B-1


Appendix BComponent Resistance Tables

Minimum and maximum resistance (R) of common melt unit components,hoses and applicators

Unless otherwise specified, resistance values are measured at 20° + 5° C(68° + 10° F).

Table B-1 Tank Heater Resistance

Voltage Heater Ohms

230 12538 136.8–158.4

Table B-1 Motor Resistance

RPM Hz Voltage Ohms

36/44 50/60 200–230 76−82

Table B-1 Heater Resistance for OP Hose

Part No. (VAC) Ohms @ 6 ft

Capillary Sensor26309−06−N (230 VAC) 385–40

Component Resistance TablesB-2


DECLARATION of CONFORMITY(For CE Certified Adhesive/Sealant Application Equipment)

PRODUCT:

LS10E Muller Martini PreMelter

APPLICABLE DIRECTIVES:

98/37/EC (Machinery Directive)73/23/EEC (Low Voltage Directive)89/336/EEC (Electromagnetic Compatibility Directive)

STANDARDS USED TO VERIFY COMPLIANCE:

EN ISO 12100EN563EN60204−1

PRINCIPLES:

This product has been manufactured according to good engineering practice.

The product specified conforms to the directive and standards described above.

Date: 6 September 2005

Donald J. McLane, Senior Vice President

Nordson Corporation � Westlake, Ohio DOC 037

ls10 premelter for muller martini -...

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